evaluation of the corrosion at early age in reinforced...

Int. J. Electrochem. Sci., 7 (2012) 588 - 600

International Journal of

ELECTROCHEMICAL SCIENCE

www.electrochemsci.org

Evaluation of the Corrosion at Early Age in Reinforced

Concrete Exposed to Sulfates

M.A. Baltazar-Zamora1,*

, G. Santiago H1, C. Gaona Tiburcio.

5 E.E. Maldonado-Bandala.

1,

C. P. Barrios-Durstewist3, R. E. Núñez-J

3, T. Pérez-López

4, P. Zambrano R

5.,

F. Almeraya-Calderón2,5

1 Universidad Veracruzana, Facultad de Ingeniería Civil-Xalapa, Circuito Gonzalo Aguirre Beltran s/n,

Zona Universitaria 91090, Xalapa, Veracruz, México 2 Centro de Investigación en Materiales Avanzados SC (CIMAV), Avda. Miguel de Cervantes 120,

Complejo Industrial Chihuahua, 31109 Chihuahua, México 3Facultad de Ingeniería- Los Mochis. Universidad Autónoma de Sinaloa. Los Mochis, Sinaloa, México

4 Centro de Investigaciones en Corrosión. Universidad Autónoma de Campeche. Campeche, México.

5 Universidad Autónoma de Nuevo León. FIME - Centro de Innovación e Investigación en Ingeniería

Aeronáutica. Av. Universidad s/n. Ciudad Universitaria. San Nicolás de los Garza, Nuevo León,

México *E-mail: [email protected]

Received: 26 November 2011 / Accepted: 17 December 2011 / Published: 1 January 2012

One of the mainly corrosion mechanisms in reinforced concrete structures (RCS) is the attack by

sulfates, due to the cracking that cause this attack, is accelerates the penetration of the sulfate ion in the

RCS’s, and causing depassivation of steel reinforced and generate the formation of electrochemical

cells, triggering the corrosion of reinforcement steel. However, the present work shows the results of

the electrochemical evaluation of reinforced concrete specimens expose in a 3 to 5% (Na2SO4)

solutions during 120 days. The concrete was elaborated with water/cement ratio of 0.4, 0.5 and 0.6.

The results obtained with the linear polarization resistance (LPR), shown that at early age the attack by

sulfates is negligible and there is no difference between the different w/c, and the concentrations of

sulfates for a well performance of the concrete under study

Keywords: Concrete, Sulfates, W/C ratio, Corrosion Rate, Potential

1. INTRODUCTION

The corrosion in the subsoil is influenced mainly by the oxygen availability, the pH, the soil’s

resistivity, the microbiology activity; however the water presence is a requirement to get a corrosion

cell, so the minerals contains of the clays are a mainly cause of corrosion for the AISI 1018 steel. The

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Int. J. Electrochem. Sci., Vol. 7, 2012

589

montmorillonite and illites clays retain more water than the kaolinite clay what is more effective for

the deterioration of metals [1], also coupled with the fact of the presence of salts in nature commonly

find in these kind of soils as are sodium sulfate (Na2SO4), potassium (K2SO4), calcium (CaSO4) or

magnesium (MgSO4) or dissolved in water adjacent to the reinforced concrete structure (RCS), which

can attack hardened concrete [2].

The sulfate ions incoming to the concrete and attack the cementitious materials accelerating the

degradation of concrete which can allow the steel reinforced is exposed the environment originated in

this way the corrosion. The sulfate ion is mainly in sea water, in industrial wastewater; in concrete

cooling towers can also be a potential source of sulfate attack due to the evaporation of water

replacement. In groundwater rarely appears free sulfate ion, normally is found on salts, namely, the

sulfates. [3-5].

The presence of sulfate ions in water that is in contact with the hardened paste of cement can

increase considerably the solubility of components of the paste and cause, one hand, the development

of concrete degradation by leaching and on the other hand, the presence of sulfates can cause a reaction

base change, during which the sulfate cation will be replaced by Ca2+

, originating the concrete

degradation by ion exchange reaction. Under certain circumstances may occur that the presence of

sulfates leads to a degradation by expansion due to the formation of other stables components in the

hardened mass of cement [6].

The two effects of sulfates attack on concrete components best known are: the formation of

ettringite (trisulphate calcium aluminate 32-hydrated, CAO·Al2O3·3CaSO4·32H2O) and gypsum

(hydrated calcium sulfate, CaSO4· 2H2O). The formation of ettringite can generate an increase in solid

volume exerting an expansive action in the pores of concrete (especially in the surface layers) up to

17.7%, causing expansion and cracking. If the solution of sulfates causes the attack contains

magnesium sulfate, ettringite and gypsum in addition to, brucite (magnesium hydroxide Mg (OH)2)

occurs that produces a volume increase of approximately 19.9%. potentializing the deterioration of the

structure[7].

Due to this cracking is accelering the penetration of the sulfate ion in the RCS’s, and causing

depassivation of steel reinforced and generate the formation of electrochemical cells, triggering the

corrosion of reinforcement steel, can reach to the collapse of the structure. Concrete is usually attacked

by sulfates has a characteristic whitish appearance. Going penetrating little by little giving a loss of

stiffness and strength of concrete. These effects are shown as the most frequent problems in the

preservation and conservation of RCS’s.

There are some studies where they have studied the corrosion of RCS’s on sulfates solutions

[8-15], however there is not study about the development of corrosion at an early age, is for this reason

the importance of generating knowledge in the behavior or reinforced concrete response to the

presence of aggressive agents in this case sodium sulphate at an early age, allowing a clear idea of the

shares to be used to predict damage to the structure, and thus meet de durability for which the structure

was designed.


590

2. EXPERIMENTAL

2.1 Design of Concrete mixes and materials

The method used for the design of concrete mixtures was established by the method ACI 211.1

[16], and which is based primarily on the physical characteristics of materials and aggregates used in

mixtures. These were determined according to Mexican standards of ONNCCE, in Table 1 shows the

physical characteristics of aggregates.

Table 1. Physical characteristics of aggregates used in the mix

Physical Property Coarse

Aggregate

Fine

Aggregate

Specific Gravity (gr/cm³) 2.32 2.66

Dry-rodded weith (kg/cm³) 1380 - - -

Absortion (%) 4 3.8

Fineness Modulus - - - 2.7

Maximum Aggregate Size (mm) 19 - - -

It was used a Portland cement CPC 30R type according to regulations NMX-C-414-ONNCCE-

2004 [17], and the mixing water was obtained from the drinking water network, three different

mixtures were prepared with water/cement ratio from 0.40, 0.50 and 0.60. Material quantities for each

concrete mixture are shown in Table 2.

Table 2. Proportioning of concrete mixtures (for 1 m3)

Materials (kg) Water/Cement Ratio

0.40 0.50 0.60

Water 209 209 209

Cement 513 410 342

Coarse Aggregate 1035 1035 1035

Fine Aggregate 606 711 765

2.2 Characterization of concrete in fresh and hardened state

Was performed the characterization of concrete in fresh and hardened state. In Table 3 are

listed the tests performed and their corresponding standards.


591

Table 3. Physical and mechanics properties of concretes.

Test Water/Cement Ratio

0.40 0.50 0.60

Slump (NMX-C-156-1997-ONNCCE) 7 cm 11 cm 13 cm

Temperature (ASTM C 1064) 24 ºC 23.5 ºC 22 ºC

Density (NMX-C-105-1987) 2254 kg/m3 2236 kg/m

3 2192 kg/m

3

Mechanical strength (NMX-C-083-ONNCCE-2002) 43.5 MPa 33.4 MPa 25.8 MPa

2.3 Specimens and Measurement Methods

Were performed cylindrical specimens of 1530 cm (see figure 1) Two 3/8 in. (9.3-mm

diameter) AISI 1018 steel bars, symmetrically embedded in the specimens, were used as working

electrodes during the measurements, with one of the steel bars acting as working electrode (WE) and

the other as counter electrode (CE). A copper-copper sulfate (Cu/CuSO4) electrode was used as

reference (RE). An active area of 5 cm2 was marked on the working electrodes with epoxy resin, thus

isolating the triple mortar/steel/atmosphere interface to avoid possible localized corrosion attack due to

differential aeration. The specimens were immersed in a 3 to 5% (Na2SO2) solutions for 120 days.

V

PI

30.0 cm

1.5 cm

27.0 cm

1.5 cm

3.5 cm

15.0 cm

2.0 cm

INSULATING

RECE

WE

INSULATING

3.0 cm

7.1 cm

3.0 cm

EX

PO

SE

D A

RE

A 8

0 c

m

2

A: AmmeterP: PotenciostatV: VoltmeterWE: Working ElectrodeCE: Counter ElectrodeRE: Reference Electrode

Figure 1. Scheme of the prismatic specimen used.


592

Electrochemical evaluation study of the specimens was carried out with electrochemical

techniques of corrosion potential (Ecorr) according to ASTM C 876-99 standard ]18] and the corrosion

rate with the technique of linear polarization resistance (LPR) according to the equation Stern-Geary

[19], applying ΔE±20 mV at a polarization rate of rate 0.16 mV s-1

; the constant B was 26 mV.

Corrosion levels were defined according to the Durar Network Specifications (21). For icorr<0.1 µA

cm-2

passivity, for 0.1 µA cm-2

<icorr<0.5 µA cm-2

low corrosion, for 0.5 µA cm-2

<icorr<1.0 µA cm-2

high corrosion, and for icorr>1.0 µA cm-2

very high corrosion. An ACM Instruments

potentiostat/galvanostat/ZRA; with a Cu/CuSO4 reference electrode.

The nomenclature used in this research is shown in Table 4.

Table 4. Nomenclature of specimens.

Media Exposure Water/Cement Ratio

0.40 0.50 0.60

Water 4B 5B 6B

Solution to

3% of Na2SO4 43S 53S 63S

Solution to

5% of Na2SO4 45S 55S 65S

3. RESULTS

0 2 4 6 8 10 12 14 16

-500

-400

-300

-200

-100

0

Curing

10% Probability of Corrosion

Uncertainty of Corrosion


4B

43S

45S

Eco

rr (

mV

vs

Cu

/Cu

SO

4)

Time (weeks)

Figure 2. Corrosion potential (Ecorr) versus time for steel bars embedded in concrete of water/cement

ratio 0.40, (4B) exposed in H2O, (43S) exposed in Na2SO4 to 3% and (45S) exposed in Na2SO4

to 5%.


593

Figure 2 shows the behavior of Ecorr in a concrete of water/cement ratio 0.40 ( f’c=43.5 MPa),

exposed after four weeks of curing at different aggressive media, are perfectly identifies the effects of

exposure to sodium sulfate attack in different concentrations in thermodynamic or probabilistic

behavior, moreover is observed as the control specimen 4B from his immersion in curing stage shows

a continuing trend towards more positive values, starting with a potential of -140 mV at week 1 and

stabilized in week 15 with values close to -80 mV indicating a steel in passive state with 10%

probability of corrosion according to the standard, however the two specimens immersed in sulphate

solutions after the curing stage where they presented a noble o passive behavior, they present a

tendency towards more negative values of corrosion, observing the effect of aggressive environment is

also shown in the 43S specimen two periods of activation-passivation-activation the first of the week

10 to 15, this is related to the entry of sulfate ions and the reaction of them with products generated in

the process of hydration. For specimen 45S is identified a single period of activation-passivation-

activation that is generated from week 6 to 12, this effect is related to the absorption of sulphates.

Figure 3 shows the behavior of the corrosion potential (Ecorr) of reinforcing steel embedded in

concrete of water/cement ratio 0.50 (f’c=33.4 MPa), exposed in solutions to 3% and 5% in Na2SO4 and

H2O. Is observed that the specimen 5B from its immersion in curing stage, shows a continuing trend of

noble values of corrosion potential of -180 mV at week 1, ending at week 15 with a value of -100 mV,

indicating a steel in passive state with 10% probability of corrosion according to the standard ASTM C

876-99. The two specimens: 53S y 55S immersed in solutions to 3% and 5% of Na2SO4 respectively,

they present an almost identical behavior to week 13, with a trend towards more noble potential in

curing stage with values from -190 mV to -150 mV, with a period of activation-passivation-activation

from week 5 to 13, where the specimen 55S continues the trend to more negative values until week 15

and the specimen 53S presents more noble values to a steel passivation process

0 2 4 6 8 10 12 14 16

-500

-400

-300

-200

-100

0

5B

53S

55S

Eco

rr (

mV

vs

Cu

/Cu

SO

4)




Curing

Time (weeks)

Figure 3. Corrosion potential (Ecorr) versus time for steel bars embedded of water/cement ratio 0.50,

(5B) exposed in H2O, (53S) exposed in Na2SO4 to 3% and (55S) exposed in Na2SO4 to 5%.


594

Figure 4 shows the corrosion potentials (Ecorr) obtained from the last group of specimens with

water/cement ratio 0.60 (f’c=23.5 MPa), like the previous two groups (Figures 3 and 4), the three

specimens shown a tendency to values more noble of potential corrosion (more positive) indicating a

passivation of the steel for the specimen 6B along the period of continuous exposure to the trend of

more positive values of Ecorr, reaching values of -100 mV at the end of the exposure period. In this

group we can see the effect of the concentration of sulfate ions or aggressive environment and its

relation to the quality of concrete, is more permeable than those analyzed in figures 3 and 4, so that the

specimen 63S shows a tendency towards more negative values from the first week of exposure to 3%

solution of Na2SO4, having values from -70 mV to reach -180 mV at the week 15, however, the most

negative values are presented by the specimen 65S with a trend towards more negative values than

those reported in the specimen 63S from its immersion to 5% solution in Na2SO4, with a potential of -

72 mVat week 4 to reach a potential of -120 mV indicating a 50% probability of corrosion.

0 2 4 6 8 10 12 14 16

-500

-400

-300

-200

-100

0

6B

63S

65S

Eco

rr (

mV

vs

Cu

/Cu

SO

4)




Curing

Time (weeks)

Figure 4. Corrosion potential (Ecorr) versus time for steel bars embedded of water/cement ratio

a/c=0.60, (6B) exposed in H2O, (63S) exposed in Na2SO4 to 3% and (65S) exposed in Na2SO4

to 5%.

Figure 5 shows the behavior of corrosion rate (icorr) for a concrete of water/cement ratio 0.40

(f’c=43.5 MPa), exposed to different media, H2O as the control, solution to 3 and 5 % of Na2SO4 as

aggressive solutions. For specimen 4B (the control) are reported values for icorr of 0.22 µA/cm² at

week 1 to reach 0.10 µA/cm² at week 4, to remain from week 5 to week 15 with icorr of 0.06 µA/cm²;

for specimen 43S have values of icorr of 0.14 µA/cm²; at week 1 to remain in a passive state with icorr of

0.04 µA/cm² during the entire period of exposure to 3% solution of Na2SO4. For specimen 45S

exposed to 5% solution of Na2SO4 presents in the curing stage values from icorr of 0.14 µA/cm² to icorr

of 0.05 µA/cm², value which is maintained throughout the period of exposure to aggressive media

(week 5 to 15), having a passive state of steel reinforcement. Can be observed from this figure that all

the specimens are in the passive state, but have small differences of icorr depending on types of media


595

that have, presenting the lowest values which were exposed to sulphates and related to the absorption

of sulfate ions that contributed to the formation of a passive layer stronger than that formed in the

specimens immersed in H2O as control specimens.

0 2 4 6 8 10 12 14 160.01

0.1

1

Curing

High Corrosion

Low Corrosion

Passivity 4B

43S

45SCu

rren

t D

en

sity

(i c

orr),

A

/cm

2

Time (Weeks)

Figure 5. Corrosion rate (icorr) of the specimens of water/cement ratio 0.40, (4B) exposed in H2O,

(43S) exposed in Na2SO4 to 3% and (45S) exposed in Na2SO4 to 5%.

0 2 4 6 8 10 12 14 160.01

0.1

1

5B

53S

55S

Time (Weeks)

High Corrosion

Low Corrosion

PassivityCuring

Cu

rren

t D

en

sity

(i c

orr),

A

/cm

2



In the Figure 6 can be observed the corrosion rate (icorr) of the specimens of water/cement ratio

0.50 (f’c=33.4 MPa) exposed to different solutions, H2O as the control, solution to 3 and 5% of

Na2SO4 as aggressive environments. In the specimen 5B (or control) are reported values from icorr of


596

0.58 µA/cm² at week 1 to reach 0.27 µA/cm² at week 4 to be located in low corrosion with values of

0.16 and 0.12 µA/cm² at weeks 5 and 6 for maintain from week 7 in the passive estate with a value of

icorr to reach 0.08 µA/cm² at week 15. For specimen 53S were obtained values in the curing stage of

icorr ranging from 0.57 µA/cm² in week 1 to 0.09 µA/cm², to be located in a passive zone with values of

icorr from 0.06 to 0.05 µA/cm² during throughout the period of exposure to 3% solution of Na2SO4, the

specimen 55S that was exposed to 5% solution of Na2SO4 presents in the curing stage values of icorr

from 0.63 to 0.06 µA/cm², to maintain icorr of 0.05 µA/cm² during throughout the period of exposure to

aggressive environment, is observed that all specimens are found after the curing stage in the passive

state of steel reinforcement.

In the Figure 7 can be observed the corrosion rate (icorr) of the specimens of water/cement ratio

0.60 (f’c=23.5 MPa), and just like those shown in figures 6 and 7 exposed to different environments,

H2O as the control, solution to 3 and 5% of Na2SO4 as aggressive environments, can be observed how

the specimen 6B (or control) reports values from icorr of 0.59 to 0.19 µA/cm² in the curing stage from

the week 1 to week 4 to show low corrosion even at weeks 5 and 6 with values icorr of 0.13 µA/cm² and

icorr of 0.10 µA/cm² respectively. And from there placed with icorr during throughout the period of

exposure (weeks 7 to 15) from 0.09 µA/cm² to 0.08 µA/cm², with respect to the specimen 63S presents

values of icorr in the curing stage, ranging from 0.68 µA/cm² at week 1 to 0.08 µA/cm² at week 4, to

locate in the passivity zone from week 5 to 15 with values of icorr ranging from 0.08 µA/cm² to 0.07

µA/cm², for the specimen exposed to 5% in Na2SO4 presents in the curing stage values of icorr ranging

from 0.70 µA/cm² to 0.06 µA/cm², and remain there throughout the study period, indicating a passive

state of steel reinforcement as the other two specimens, it seems that the lower quality of this concrete

evidence of the ability of sulfate ion absorption by the concrete under study, and thus the formation of

a more resistant layer related to the smaller value of corrosion kinetics reported for specimens exposed

to a higher concentration of Na2SO4.

0 2 4 6 8 10 12 14 160.01

0.1

1

6B

63S

65S

Cu

rren

t D

en

sity

(i c

orr),

uA

/cm

2

Time (Weeks)

High Corrosion

Low Corrosion

PassivityCuring

Cu

rren

t D

en

sity

(i c

orr),

A

/cm

2




597

4. DISCUSSION

In the Figure 8 compares Ecorr vs icorr, is observed as in the curing stage are presented values of

icorr indicating a low corrosion, for the three specimens under study and at the same corrosion potential

values that indicate 10% probability of corrosion. As the specimen control remained immersed in H2O

presents a curve with tendency to decrease toward zeros on both axes: Ecorr vs icorr, confirming the

passive state of steel, agreeing well with the standard that interprets these values: ASTM C 876-99 in

corrosion potential (Ecorr) and the Durar Network Specifications [20], in the parts that corresponds to

the corrosion rate (icorr). For the specimens exposed to 3% and 5% in Na2SO4, they present a behavior

between them, with icorr in the curing stage indicating low corrosion to decrease when exposed to

aggressive environment toward more positive values (left) to move toward more negative values

(right) to move toward the area of uncertainty, but indicating negligible corrosion values of icorr.

Described in the graphics for these two specimens a sort of “L”, where precisely the bottom (exposure

time) can be associated to the period of initiation of useful life of Tuutti [21], where the level of

corrosion is negligible.

-50 -100 -150 -200 -250 -300 -350 -400

0.1

1

Very High Corrosion

90

% P

ro

ba

bility

of C

orro

sion

Un

certa

inty

of C

orro

sion

10

% P

ro

ba

bility

of C

orro

sión

Passivity

Low Corrosion

High Corrosion

4B

43S

45S

Cu

rren

t D

en

sity

(i c

orr)

uA

/cm

2)

Corrosion Potential (Ecorr

) mV vs Cu/CuSO4

Figure 8. Current density (icorr in µA/cm²) versus corrosion potential (Ecorr in mV) of the specimens of

water/cement ratio 0.40, (4B) exposed in H2O, (43S) exposed in Na2SO4 to 3% and (45S)

exposed in Na2SO4 to 5%.

In the case of lower-quality specimens, water/cement ratio 0.50 and 0.60, (Figures 9 and 10),

are identified high and low corrosion values for both grades of concrete quality in the curing stage,

related to the formation of the passive layer, giving the potential more negative than -200, which

indicates according to the standard ASTM C-876-99 a 10% probability of corrosion, both concretes

0.50 and 0.60 when exposed to 3% and 5% solution in Na2SO4 and after de decrease in the curing stage

of its corrosion rate (icorr), they present values that indicate passivity according to literature, but just


598

like noted in figure 9, tend in the first weeks of exposure to aggressive environment towards more

positive values of (Ecorr), but to go forward in time these values become more negative, again presents

a sort of “L”where part of exposure as mentioned in the previous paragraph corresponds to the period

of initiation of Tuutti useful life .

-50 -100 -150 -200 -250 -300 -350 -400

0.1

1

Very High Corrosion9

0%

Pro

ba

bility

of C

orro

sion

Un

certa

inty

of C

orro

sion

10

% P

ro

ba

bility

of C

orro

sión

Passivity

Low Corrosion

High Corrosion

5B

53S

55S

Cu

rren

t D

en

sity

(i c

orr)

uA

/cm

2)


) mV vs Cu/CuSO4

Figure 9. Current density (icorr in µA/cm²) versus corrosion potential (Ecorr in mV) of the specimens of

water/cement ratio 0.50, (5B) exposed in H2O, (53S) exposed in Na2SO4 to 3% and (55S)


-50 -100 -150 -200 -250 -300 -350 -400

0.1

1

Very High Corrosion

90

% P

ro

ba

bility

of C

orro

sion

Un

certa

inty

of C

orro

sion

10

% P

ro

ba

bility

of C

orro

sión

Passivity

Low Corrosion

High Corrosion

6B

63S

65S

Cu

rren

t D

en

sity

(i c

orr)

uA

/cm

2)


) mV vs Cu/CuSO4

Figure 10. Current density (icorr in µA/cm²) versus corrosion potential (Ecorr in mV) of the specimens

of water/cement ratio 0.60, (6B) exposed in H2O, (63S) exposed in Na2SO4 to 3% and (65S)



599

5. CONCLUSIONS

In concrete at early ages there is no a clear difference between the different relations in the

water/cement ratio (0.40,0.50,0.60), when they are exposed to sulfates (solutions to 3 and 5% in

Na2SO4).

The electrochemical behavior of specimens under study was favorable according to the results

obtained of Ecorr vs icorr as brand the model of useful life of Tuutti and tests performed.

Was not observed a significant behavior in terms of corrosion rate according to the different

relations of water/cement ratio. The concretes exposed to Na2SO4 always showed lower corrosion rates

that the concretes in H2O. The deterioration caused by corrosion at an early age in negligible according

to the results obtained with technique of LPR.

Is associated with the formation of a passive layer more resistant in specimens exposed to

sulfates, presenting values of icorr lower in magnitude over the specimens exposed in H2O.

ACKNOWLEDGEMENTS

The authors externalize their gratitude to PROMEP for the financial support granted for the

development of this research Project through Incorporation of New PTC PROMEP/103.5/07/2753.

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